Apparatus for the manufacture of sodium carbonate monohydrate



March 31), 1936. l w. H. ALLEN Er AL 2,035,441' APPARATUS FOR THE MANUFACTURE oF soDIUM CARBONATE MONOHYDRATE Qrignal Filed Jan. 3l, 1930 SCFI/BEI coaLER Fg' .Z 16 11 l; sarunnvrn vwvu ne., Cl* Na. 6a lla-HNI 5f I@ /Illorneys Patented Mar. 31, 1936 UNITED STATES PATENT OFFICE' APPARATUS FOR THE MANUFACTURE ,0F SODIUM GARBONATE MONOHYDRATE Original application January 31, 1930, Serial No.

424,816, 110W Patent No. 1,937,937.

Divided and this application March 8, 1933, Serial No.

9 Claims.

This invention relates to an apparatus for producing sodium carbonate monohydrate and sodium sulphate dekahydrate from mixtures of the same, together with other salts, such as sodium chloride, which mixtures may exist in solid form or in solution.

This application is a division of our copending application, Serial No. 424,816, led January 3l, 1930, now Patent No. 1,937,937.

We have devised the apparatus of this invention for the particular purpose of separating so dium carbonate monohydrate, Glaubers salt and sodium chloride from salt mixtures which are produced by the manipulation of Searles Lake brine in an apparatus for producing potash and borax from the brine. However, the apparatus may be employed upon similar mixtures obtained from other sources. k

Certain features of the apparatus herein illustrated, While of particular utility in the recovery of sodium carbonate monohydrate from complexes of the same together with sodium sulphate dekahydrate and sodium chloride, may also be applied for recovering other materials or salts from solution.

Our United States Letters Patent No` 1,836,426, issued December 15, 1931, sets forth in full and exact detail methods for manipulating solutions and solid mixtures containing in preponderance the chloride, sulphate and carbonate of sodium. By the process of that invention, such mixtures are manipulated, by means of heating, cooling, etc., in a cy-clical or semi-cyclical manner, for the recovery of Glaubers salt and the production of a solution termed hot carbonate liquor, said hot carbonate liquor being essentially saturated with respect to sodium carbonate monohydrate, sodium chloride and a double salt of sodium carn bonate and sodium sulphate termed burkeite, Liquor of such composition contains relatively high percentages ,of sodium carbonate and sodium chloride, and a relatively low percentage of sodium sulphate. The process of the aforementioned application further sets forth a method for recovering from said hot carbonate liquor substantial quantities of essentially pure sodium carbonate in the form of sal-soda, said method comprising refrigeration of the het carbonate liquor under suitable conditions.

Sal-soda or sodium carbonate dekahydrate is not, of itself, an important commercial commodity, andsuch is generally transformed to the anhydrous form, thereby producing the wellknown soda-ash of commerce. It is common practice in the art to produce. the highly desirable dense form of soda ash by drying or dehydratlng sodium carbonate monohydrate. Such operation probably results in'a dense soda ash by virtue of retaining the crystal habit of the previously formed sodium carbonate monohydrate.

One method commonly practiced for reducing sal-soda to the monohydrated salt, from which very dense soda ashy may be produced, comprises dissolving said sal-soda in water and boiling off the excess water, With consequent precipitation of the desired sodium carbonate monohydrate. Such process possesses the disadvantage that considerable heat is required and also that said manipulation results in rather serious coating of the heating elements of the. evaporator with the precipitating salt.

One of the objects of the present invention is the production ofsodium carbonate monohydrate directly from hot carbonate liquorY or similar liquors high in sodium carbonate, thus eliminating the expensive steps of refrigerating said liquor for the production of sal-soda and also eliminating the undesirable step of heating and boiling Water from said sal-soda, for its oo nversion into sodium carbonate monohydrate.

By the apparatus of our, invention,'we treat suitable carbonate containing liquors With ammonia, causing the precipitation of sodium carbonate monohydrate directly therefrom. Another object of our invention is to further supply equipment and means for carrying out this object. These and other objects and advantages of the present invention will become obvious with the following disclosure. Y

It has long been knownV that the addition of ammonia to aqueoussolutions greatly reduces the solubilities of both sodium sulphate and sodium carbonate in the same, Whereas the solubility of sodium chloride is not appreciablyv affected. Based upon this information, it. has been attempted to separate these three salts from mixtures thereof in solution by the fractional and successive precipitation of sodium sulphate and sodium carbonate in pure form by the addition of ammonia while leaving the chloride in the ammoniacal mother liquor. The ammonia would then be recovered by distillation and returned to the process, While the sodium chloride would be crystallized by evaporation of the end-liquor.

We have found, however, that sucha process of fractional and successive precipitation of sodium 4sulphate and sodium carbonate fromy mixed solution is entirely inoperable due tov the formation of the double salt burkeite,

(Na2CO3.2Na2SO4), and its low solubility Vin the presence of ammonia.

We have discovered, however, that ammonia may be used for the precipitation of essentially pure sodium carbonate monohydrate from solutions of sodium carbonate, sodium sulphate and sodium chloride by first bringing the solution essentially to saturation with burkeite, sodium carbonate monohydrate and sodiuln chloride at a higher temperature. By this step of preliminary treatment, sodium sulphate, present in the original solution or raw material, is reduced to a relatively small value through precipitation in the form of burkeite, said burkeite being then removed from the hot liquor and returned to the process for the recovery of its component parts. The clear hot liquor is then cooled to a lower temperature whereby a small amount of sodium chloride may be crystallized. The latter may be removed by filtration or other suitable means, or sulcient water may be added either prior to or during cooling to prevent this separation of chloride.

Liquor thus processed may then be successfully treated with ammonia to precipitate a relatively large portion of the sodium carbonate in the form of essentially pure monohydrate. Care must be taken, however, not to add an excess of ammonia, otherwise burkeite will be precipitated in sufficient quantity to contaminate the resulting product. The requisite quantity of arnmonia to be added depends on the conditions chosen for carrying out the process of our invention, set forth in our co-pending application above noted, of which this is a division.

According to the precepts set forth in said patent, abovernoted, the higher the liquor, essentially saturated with burkeite, sodium carbonate monohydrate and sodium chloride, is heated, the greater will be the precipitation of burkeite and the reduction of sodium sulphate content. In order to obtain satisfactory results with the present process of precipitating sodium carbonate monohydrate from the saline liquor by the addition of ammonia thereto, it is requisite that very little sodium sulphate be present in said liquor. To this end it is necessary to heat the liquor so saturated, higher than would be necessary for carrying out the process of the aforementioned patent, temperatures from 60 to 100 being employed in the present case.

It is an object of the present invention to provide an apparatus for carrying out such a process without appreciable loss of ammonia. In the process of our co-pending Aapplication referred to, it is dicult to separate the sodium carbonate monohydrate from the ammoniacal mother liquor Without loss of ammonia. Ordinary methods of separation, such as centrifuging or vacuum filtration, result in a large loss of ammonia so as to make the process an economical failure. Y

In order to more clearly describe our invention, we submit the following specific example, but we wish it understood that we do not limit the scope of our invention thereby.

The apparatus is preferably used in treating certain salt complexes from Searles Lake brine, called clarifier salts, which consist mainly of sodium carbonate, sodium sulphate and sodium chloride, the greater part of the carbonate and sulphate being in the form of burkeite. The process to be carried out in the apparatus of this invention is as follows:

The salts are first leached to remove substantially all of the sodium chloride, as later explained. This leaching is accomplished by a solution termed hot sulphate liquor, produced in a subsequent step of the process to which step the leached clariiier salts are re-cycled from the first operation. The leached clarifier salts contain approximately 34 percent sodium carbonate and 66 percent of sodium sulphate on a dry basis. However, the composition of the leached clarifier salt is subject to somewhat wide variation. To 1000 pounds of complex we add 1721 pounds of water and stir the mixture while maintaining the temperature between 22 and 25 C. Under these conditions of percentage of leached clarifier salt, water and temperature, the complex is digested within that field or condition of operation where sodium sulphate dekahydrate or Glaubers salt is the constituent which precipitates first from the solution upon the solution becoming supersaturated. In this operation when the coniposition of the solution reaches saturation with sodium sulphate dekahydrate, this salt is precipitated while further burkeite is dissolved from the mixture and its sodium sulphate content reprecipitated as Glaubers salt. The sodium carbonate content of the burlseite remains in solution and thereby a solution is obtained having a greater ratio of carbonates to sulphates than that which exists in the raw material. 'Said solution, freed from suspended solids is termed cold sulphate liquor; when heated to a higher temperature it is termed hot sulphate liquor.

At the same time Glaubers salt is attained which may be readily Washed to produce a pure and Valuable product. The conditions of operation as described are selected so that as a final result of the leaching and dissolving operation, the solution comes close to that of a saturated solution at the transition point between Glaubers salt, sodium carbonate dekahydrate and the deuble salt burkeite. The transition point of the solution, entirely free of sodium chloride, is substantially 25 C. Approximately 825 pounds of Glaubers salt is precipitated in these dissolving and digesting operations.

Approximately 1896 pounds of liquid is obtained which we term cold sulphate liquor and has the following composition:

Pounds Sodium carbonate 340 Sodium sulphate 296 Water 1260 This cold sulphate liquor is then heated to some suitable temperature so that the composition is within the field that burkeite precipitates. The exact temperature of treatment is variable over a considerable limit.

The higher the temperature of the treatment, the lower will be the sulphate content in the solution from which sodium carbonate monohydrate is to be precipitated. In order to secure an efiicient recovery of the sodium carbonate monohydrate, we prefer to heat the solution to a temperature between 60 and 100 C.

This hot sulphate liquor is then brought to saturation with respect to sodium chloride. The saturation of the solution with sodium chloride causes the solution to precipitate burkeite which operation removes the majority of the residual sulphate content of the liquor. In saturating the hot sulphate liquor with sodium chloride, the sodium chloride required is preferably provided, in part at least, by the sodium chloride content of the original clarifier salts. For this purpose,

theclarier salt to be processed still containing the sodium chloride content is leached with the hot sulphate liquor. In certain cases, the sodium chloride content of the clarer salt may be sufiicient to saturate the hot liquor. In other cases, additional sodium chloride may be added. In any case, the amount of sodium chloride brought in contact with the hot sulphate liquor should be sucient vto produce saturation. The burkeite content of the clarifier salt remains undissolved and is collected with the burkeite precipitated from the hot liquor. It is this mixture of leached burkeite from clarier salt and precipitated burkeite from hot liquor which isA the starting material utilized in the first operation of the process.

So far, the process as herein described is in its operationsimilar to the first operations of our mentioned issued patent, except that the temperature to which the sulphate liquor is heated for saturating with sodium chloride is somewhat higher than that preferably employed in the process of the said issued patent. For example, in the present process, we use the preferred temperature of '75 C.

The liquor remaining after separation of the burkeite and other dissolved constituents we term hot carbonate liquor. For the remaining steps of the process we take, for example,v278,000 gallons of this hot carbonate liquor. This hot carbonate liquor when produced at 75 C. has a speciiic'gravity of 1.28'and contains:

Tons Sodium carbonate 166 Sodium sulphate 14 Sodium chloride 303 Water 1000 `As stated in the prior patent, this solution is essentially saturated with sodium chloride, sodium carbonate monohydrate and burkeite at the temperature at which it is prepared, in this case, '75 C. Liquor of this or similar composition, containing considerable sodium carbonate and relatively little sodium sulphate may be successfully treated with ammonia for the precipitation of sodium carbonate without appreciable precipitation of sodium sulphate. We prefer to carry out the ammonia treatment at some moderate temperature, such as atmospheric or C., hence the afore-described hot carbonate liquor must be cooled prior to the precipitation step. While such cooling may be brought about either prior to or subsequent to the cyclical counterwashing step, to be described below, we prefer to carry out said cooling following the counterwashing Step.

In cooling the hot carbonate liquor from '75 C. to 35 C., a small amount of sodium chloride may separate if said liquor was saturated therewith at 75 C. This salt is removed from the liquor by settling, centrifuging or other suitable means. Under the specific conditions of this example, about 28 tons of salt are thus obtained. After being given a slight wash with water, this material is of suciently high purity for table salt use.

Said cooling to 35 C. or less does not bring about precipitation of the other sodium salts. In fact, such cooling actually renders the liquor unsaturated therewith, and no sodium carbonate will be precipitated until the liquor is cooled well below 20 C. Mother liquor, or the clarified iiltrate, resulting from this table salt recovery, is then ready for the ammonia treatment for the precipitation of sodium carbonate monohydrate.

The apparatus constituting Ithis invention will be most readily understood from a description of a preferred form of apparatus embodying the invention. For this purpose, we have herein described a preferred form or example of an apparatus embodying the present invention.

YIn the drawing:

Figure l is a diagrammatic view of the apparatus.

Figure 2 is an enlarged elevation mainly in vertical section of the salt settler employed in the apparatus of Figure l.

Figure 3 is a chart from which the amount of ammonia to be used in the process and apparatus may be determined.

Referring to the drawing, we pass the clear hot carbonate liquor, at the continuous rate of about 200 gallons per minute into the counterwashing chamber I9, of our settler-washer 30, by means of a suitable inlet line I. This liquor leaves the counterwashing chamber I9 by way of a peripheral launder 3| and suitable outlets 2. Said outlets are connected to a suitable common collecting line by whichthe liquor is conducted to a suitable cooler and sodium chloride removal system I5. From the sodium chloride recovery system the clear liquor passes via line 5 to a suitable scrubber 6. This scrubber may be of any suitable design and is imposed in the cycle for the purpose of salvaging ammonia gas from various sources. Liquor flows from the bottom of the scrubber through line 1 to the precipitator 9 entering through an enlarged inlet 8.

Ammonia bearing gas is introduced into the precipitator by way of line I0, leading from a suitable source of supply, such as an ammonia still. The ammonia is very rapidly absorbed by the liquor in the precipitator, and it has been found necessary to introduce the ammonia at a point below the surfaces of the liquor. The absorption of ammonia causes a portion of the carbonate content of the liquor to be precipitated in the form of granular sodium carbonate monohydrate. This reaction evolves a considerable quantity of heat, and in addition heat is evolved bythe condensation of Water vapor present in the incoming ammonia gas, since this gas is essentially saturated with water vapor as it leaves the ammonia still or subsequent condenser.

Means must be provided, therefore, for maintaining the temperature of the liquor in the precipitator at a suitable point, such as 35 C. We do this by circulating liquor through a cooler I3 of any suitable design by means of lines Il and The correct amount of ammonia to be added to the liquor depends upon the conditions of operation, such as the temperature at which they hot carbonate liquor was prepared and the temperature maintained within the precipitator. These relations have been determined for a Wide variety of conditions and are shown graphically in Figure 3. l

Within ordinary ranges, the temperature at which the precipitation of the monohydrate is carried out has little effect upon this curve, so that for practical purposes this one curve may be used at all precipitator temperatures between say, 20 and 50 C. Any large excess of ammonia above that indicated by the graph may cause the precipitation of an appreciable amount of sodium sulphate, as burkeite, which would not be re-dissolved by counterwashing with hot carbonate liquor, as herein described, and would contaminate the resulting soda ash.

Under the conditions of the specific example chosen, we add a maximum of pounds of ammonia (NI-I3) per 100 pounds of water present in the resulting mother liquor. The composition of the required -amount of ammoniacal gas is approximately as follows:

Tons

Ammonia 100 Water vapor 14 Inert gas 1 Total 115 This amount is controlled by varying the rates of oW of liquor to and from the precipitator through lines 'I and I6, respectively, as well as the rate of flow of ammonia gas entering the precipitator through line I0.

While various systems of ammonia absorption may be employed with considerable degree of success, some operating under reduced and some under increased pressure, we prefer to operate at or near atmospheric pressure.

It must be understood that the present method for producing sodium carbonate monohydrate from concentrated solution is in no manner akin to the well-known process for the manufacture of sodium bicarbonate and subsequently soda ash from sodium chloride by the use of ammonia and carbon dioxide gas. In such a case, the ammonia is caused to enter into true chemical reaction with the components supplied. In the present case, ammonia, either in concentrated solution or as a gas, is added to the solution of already formed sodium carbonate. Its action of precipitation is simply a physical one, somewhat analogous to the well-known s-alting-out action of soap from solution or possibly explained as a squeezing-out action; for, ammonia gas possesses a remarkable amnity for water and consequently squeezes out many other dissolved substances in its eiort to gain its place therein. Since the ammonia does not enter into chemical reaction with the component of the present system, it may be recovered by simply applying heat to the residual liquor containing the same. This is accomplished by means o any suitable ammonia boiler, the liberated gas being again utilized as means for further precipitation of sodium carbonate monohydrate from solution.

In the handling of such a system, the accumulation of a certain amount of non-condensable gas, such as air, is practically unavoidable, and we provide means for disposing of the same without loss of ammonia. Such non-condensable gas tends to collect in the vapor space 26 above the liquor level 21 in the precipitator S. We supply suitable vent line for the removal of such, said vent lines discharging into the scrubber 6 in order to absorb any ammonia gas by means of the cold liquor passing to the precipitator. The present system maintains the pressure in space 2S slightly above that of the atmosphere; hence, the non-ccndensable gas is caused to flow over the surface of the-incoming liquor in the enlarged inlet 8. Said gas, now containing only a small amount of ammonia, passes to the scrubber E by means of vent line 2l. The remaining traces of ammonia are almost entirely removed from the non-condensable gas in the scrubber,

Afrom whence it passes to the atmosphere by way of vent 28.

A sludge consisting of the precipitated sodium carbonate monohydrate and ammoniacal mother liquor is drawn from the precipitator 9 at a suitable point, for example, by means of a pump I2 and a line I6, and is passed through Said line into the settling chamber I1 of Figure 2, which is fitted with an annular conical bottom of unusual design and import. Said bottom terminates within the chamber I9. The suspended crystals of sodium carbonate monohydrate settle out of the ammoniacal mother liquor in chamber Il and pass through the connecting annular opening I8 into the lower chamber I9, which is filled with the incoming hot carbonate liquor. Chamber I9 is also provided with a conical bottom 32 from which a small stream of a densely thickened sludge, essentially free of ammonia, is removed through an outlet 33, to a continuous vacuum lter, centrifugal or other suitable dewatering device. Filtrate from this step is returned to the process; for example, to the cooling and NaCl removal system.

The `crop of sodium carbonate monohydrate so obtained amounts to approximately 94 tons, and after a slight displacing wash with warm water it is dried in a rotary drier at about 100 to 150n C., thereby obtaining approximately 80 tons of the anhydrous salt. We have found that the soda ash produced in this way if of a high degree of purity, dense in nature and relatively free from fines. Its dustless quality results from the fact that the large crystal form of the precipitated monohydrate is essentially maintained by the resulting ash.

The ammoniacal mother liquor flows from the center of the settling chamber Il radially to the circular launder 3f. Said liquor now claried of suspended crystals, leaves the settling chamber and collecting launder by means of lines 35, passing thence to an ammonia recovery still of suitable type. This clear liquor, flowing over the launder 34, has approximately the following composition:

Tons

NazCOn 86 Na2SO4 14 NaCl 275 NH3 100 H2O 1000 Total 1475 Temperature 35 C. Specific gravity 1.18

It Will be noted that the specific gravity of this liquor is appreciably less than that of the hot carbonate liquor (spec. grav. 1.28) which overflows launder 3 I By the process as described to this point, liquor containing sodium carbonate, sodium sulphate and sodium chloride is treated (heated) for the reduction of sodium sulphate to a tolerable value, a crop of sodium chloride is recovered by cooling and a crop of sodium carbonate monohydrate is successfully precipitated in an essentially pure state by the use of ammonia. Furthermore, the precipitated sodium carbonate monohydrate is effectively and economically separated from the ammoniacal mother liquor, Without appreciable loss of either and without inconvenience to workmen employed in the process. The equipment depicted in Figure 2 is in a large measure responsible for the success of the last-mentioned results, and we wish to describe herein Vthe details of said equipment in order that one skilled in the art may be ,able tomake use of the same.

The purpose of this equipment is to settle from the ammoniacal mother liquor the precipitated crystals and to pass said crystals into a lower disposed chamber wherein the crystals are counterwashed with a suitable uid and again separated from the enveloping fluid.

For the purpose of compactness and other engineering considerations, we build the combined settler-washer as a single unit. Externally the unit comprises a right cylindrical section 20, which in the case described was 12 -feet in diameter and about 5 feet high. A steep cylindrical cone 32 is affixed to the cylindrical section 2|), forming the bottom of the unit and specically the bottom of the lower chamber I9, the angle of said cone being about 60 in the case depicted in Figure 2.

A suitable top enclosure, such as the semi-dome 2l serves to complete the external boundaries of the unit. A circular launder 3| is affixed to the upper portion of the right cylindrical section 20 near the top for the removal of clarified liquor. 'Ihe upper extremity of said launder fixes the level of the liquor within the chamber I9 at the indicated line b--b. This launder and take-off line 2 must be of sufcient size as to carry off the maximum quantity of liquor supplied to the chamber without raising the level b--b` to any appreciable extent.

A truncated conical section 22 is affixed within the upper portion of the unit, forming the bottom of the upper chamber I1. In the case described, this is likewise a 60 cylindrical conical section and is lailixed to the semi-dome cover 2|. Unless the upper section I1 is raised above the lower section, some means for insulatingthe walls forming the upper section must be provided if a large temperature difference exists. The cones 22 and 23 may be constructed with double walls, with air space between for this purpose, as shown by 25. A circular launder 34 is provided for the upper section, said launder determining the level of the liquor within the upper section, as Yshown by line c-c.

As in the case of vthe previously described launder 3|, the present one and its outlet lines 35 etc., must be of suiiicient size to carry ofi all the liquor fed to the chamber I1. The diameter of the launder of upper section I1 is, in the case described, about 8 feet.

While it is possible to terminate the cylindrical conical section 22 by truncation at or near its apex, we prefer to cut it ol at some point as represented by plane 1 -a, thereby providing an opening slightly greater than 3 feet in diameter. Over this opening we dispose annularly an inverted 60 conical section 23 having 4a base of slightly less than 3 feet, thus forming a circular or annular orice at the plane aJ-a., said orifice being in the present case about one inch in width. This conical section is held in place by webs or baffle plates 24 disposed perpendicularly between the two conical sections 22 and 23, and welded or otherwise aiflxed thereto. The webs are ernployed primarily for the purpose described, but they are also of value in preventing vortex action, and may suitably be extended a considerable height above and below the plane a-a, as shown. An annular well or leg I 8 having a width of about one inch is formed by afxing two concentric right cylindrical sections of proper diameterto the truncated cones 22 and 23 at their intersection with a plane a-a. Said cylindrical sections have, in the present case, ,a height of about eighteen inches, and are kept correctly spaced apart b-y extension of the bailles 24.

Liquor is supplied to the lower chamber I9 by means of line I, terminating in an enlarged pipe section or other suitable device 36 which serves to introduce said liquor in a quiet or orderly manner. This enlarged section may be disposed' within the space formed by the cone 23, and above the lower extremity of the depending annular well E8. A distributing cup 31 is placed at the extremity' of the inlet line IB, just below the liquor level c-c of the upper chamber' I1. Suitable vent lines 3B are provided at various points on the unit for the removal of non-condensable gas, said lines passing into the scrubber 6 of Figure 1. The inverted tank or cone 23 into which the line I terminates may also be suitably vented. inspection manholes,`such as 3 and 4, may be supplied for the chamber I1 and I9.

The principles of construction of this unit of our invention may be better understood with a more detailed explanation of the operation thereof. Various methods of filling the unit uponcommencing operation may beemployed.

Valves or plugs may be supplied for the depending leg I 8 to facilitate the first lling operations. In the circular unit the lower chamber may be filled to plane a-a, and liquor then introduced at approximately equal rates to both chambers, until filled. A constant-hydrostatichead tank, congruous with the inner chamber I1 but inverted, may obviously be employed forv more exactly precise lling work.

With the two chambers lled, we are ready to commence operations. Vent outlet lines are opened and the normal flow of ammoniacal liquor containing precipitated salt is supplied to the upper chamber through'line I6, 4and distributingl cup 31. Liquor ilows from the center of the cone to the peripheral launder 34 and in so doing drops its content of suspended crystals. The upper edge of` the launder should be essentially level and adjusting means may be supplied to that end. Liquor overflowing the launder passes outthe unrestricted take-off lines 35 to other suitablev equipment,-an ammonia boiler in thisA instance. Crystals pass downward and are deflected by the sides of the conesinto the annular well I8.

It has been mentioned in passing that the density of the ammoniacal liquor was considerably less than that of the hot carbonate liquorf It is upon this fact that the present equipment is made possible. By placing the lighter liquor, containing the solids and the greatest dissolved values (for example, ammonia) over the dense liquor substantially free of such values, we are able to maintain a static interface at the plane a-a. Said interface has been shownin the present case as corresponding approximately with the point of junction of the two conical sections, 22 and 23; although the same might have as well been shown as existing midway in the annular well I8. Due to the difference in densities of the two liquors, it is necessary that the height of the liquor in upper chamber I1 be greater than that of the lower chamber I9. This height difference in the present case calculates to about 5 inches. One of the objects of the depending annular well I8 is to compensate small errors in such calculations and variations in liq uor densities, thus assuring a perfect static balance at all times,-maintaining the interfacial plane of the two liquors within the constricted zone of the depending Well or legs.

With a properly constructed unit a surprising and most satisfactory line of demarcation is maintained at the point of junction of the two liquids; the lighter liquid being disposed above the heavier one. Unlike certain other schemes which have come to our attention, the operation of this equipment is not dependent upon the selection of an orifice or well of fixed size. We prefer to construct such well or Wells I8 of large size, in order that very little concentration of crystals will take place in passing therethrough. In other words, it is our object to cause the crystals to fall through the depending Well in a free and unobstructed manner, causing as little turbulence'and entraining as little liquor as possible. Were it not for eddy currents in such hydraulic equipment, we would construct the orifice of considerably increased size. However, to prevent undue mixing and eddying of the two liquors at the interface, we prefer to restrict such openings to 1 to 2 inches for the specific construction of a 3-foot annular well handling approximately the specified quantity of material, thus providing a cross-sectional area of about l square foot. Of course, this area is dependent upon the quantity and the settling rate of crystals produced, the latter in the present case being about 5 feet per minute.

As previously stated, quite a sharp line oi' demarcation is maintained at the interface of the two liquors, said interface being situated at or below the plane aa. Crystals pass through the depending Well I8 into the lower chamber I9. These crystals may entrain and possibly absorb a. certain quantity of the values (ammonia) of the lighter solution. Such values are removed by washing the crystals with a suitable liquor; in this case, the hot carbonate liquor which is to be subsequently treated with ammonia. To this end, We introduce the hot carbonate liquor by means of line I into the lower chamber I9. In the indicated construction in which an annular well is employed, this liquor may advantageously be introduced centrally in the manner shown, which causes all-of said liquor to pass through the curtain of crystals formed by their passage through the well I8. To this end. it is preferable that the plane of the extremity of said well be level (horizontal), causing an equal distribution of liquor throughout the descending curtain of crystals. While a small stream of hot carbonate liquor may be introduced near the extremity of the cone 32 (as shown by orice 29 on line l), to produce a clearing out effect of the lower regions, we have found that generally such an expedient is unnecessary, since the lighter liquor containing the desired values tends to pass upward with the main ascending stream to the peripheral launder 3I.

It is understood that the settling area of the several chambers should be sufficient to bring about essentially complete sedimentation of the suspended crystals from the mother liquors. In the circular unit depicted, the settling area provided for the lower chamber is considerably larger than that of the upper one in order to compensate for the increased turbulence and loss of effective settling area caused by the introduction of crystals and liquor into that chamber.

Hot carbonate liquor leaving the launder 3| containing a small amount of values carried into the lower chamber by the descending crystals,

passes to the cooling and sodium chloride recovery system, and thence to the precipitator. The liquor leaving the precipitator containing suspended crystals and high values of ammonia is introduced into the upper chamber I'I through line I6, thus completing the cycle.

Clear liquor leaving the upper launder 34 passes to an ammonia boiler which serves to recover essentially all of that valuable commodity for subsequent re-use. Liquor from which the ammonia has been expelled may be discarded, or it may be put through suitable processes for the recovery of residual values.

For example, said liquor already heated by virtue of the ammonia recovery step, may be subjected to vacuum cooling with the simultaneous removal of about 10 percent of the contained Water, without precipitating any of the dissolved saline content. Such liquor cooled to about 35 C. will have the following approximate composition:

Tons

NazCOs 86 Na2SO4 14 NaCl 2'7 5 H2O 890 Total 1265 Such liquor might Well be subjected to further refrigeration at low temperature, resulting in the recovery of over half of the remaining 86 tons of sodium carbonate as essentially pure sal soda. The sodium sulphate content being low, the hot residual liquor might likewise be employed to advantage for the manufacture of caustic soda. Another alternative consists of treating the residual liquors with an acid gas such as carbon dioxide or sulfur dioxide, subsequently recovering a valuable crop of sodium bicarbonate or sodium bisulte.

Another variation for the utilization of the residual values resides in employing the ammoniaca] liquor, leaving upper chamber II in a modied ammonia soda process.

Such liquor contains sodium chloride and ammonia, two constituents requisite for production of sodium bicarbonate by the well-known ammonia-soda process. Hence, carbon dioxide may be supplied to such liquor, in the usual equipment, for the production of sodium bicarbonate, the sodium carbonate content of the residual liquor as well as the sodium chloride content thereof contributing to the production of this valuable commodity.

While we have described our apparatus as it is used particularly in the manufacture of scdium carbonate in apparatus not necessarily limited thereto, and furthermore various modifications and changes may be made without departing from the principles of this invention, this invention includes all such modifications and changes as come within the scope of the appended claims.

We claim:

1. An apparatus for recovering precipitated salts which comprises, a displacement chamber, and means for passing into said chamber one solution, a' superimposed chamber, means for passing into said superimposed chamber another or second solution, a restricted passage leading from the superimposed chamber to the displacement chamber, means for withdrawing salts from the displacement chamber, and overflow means for the upper and lower chambers maintained at different elevations such that the restricted passage is substantially at a static interface between the liquor bodies in said chambers.

2. An apparatus for removing salts from a liquor comingled with the same, which comprises a lower chamber for washing liquid having an inlet, an outlet for removing salts therefrom and an overflow means, an upper chamber having inlet and outlet and overilow means, the upper chamber having a restricted passage communicating with the lower chamber through which the salts suspended in the liquor introduced in the upper chamber may pass into the lower chamber, the overiiow means of the upper and lower chamber being arranged to create a static interface in the passages between said chambers.

3. An apparatus for separating a solid from a liquid and washing the solid with a liquid of higher specific density without substantial comingling ofthe two liquors, which comprises a settling chamber for liquor containing the solid, an inlet means for said settling chamber, an overflow means for said chamber, and a restricted passage for a solid at the lower part of such settling chamber, a washing liquid chamber into which said passage leads, an inlet means for washing liquid into said washing chamber, an outlet means for liquor and solid at the lower end of said washing liquid chamber, and an overflow port for said washing chamber located sufiiciently close to but below the level of the overiiow means from the settling chamber so as to create a static interface between the fluids in said chambers substantially at said restricted passage.

4. An apparatus for separating solids from a liquor containing the same and washing the solids with a liquor of higher specific density without comingling the liquors substantially, which comprises a settling chamber, and means for continuously introducing the liquid and solid into said chamber, an overflow launder for said chamber, a lower settling chamber, means for continuously introducing the washing liquid into said lower chamber, an overflow launder for said lower chamber disposed slightly below the elevation of the overflow launder of the upper chamber, a restricted passage connecting the upper settling chamber with the lower settling chamber whereby a static interface is created at said passage permitting substantially solids only to pass through such passage, and a solids discharge port for said lower settling chamber.

5. In combination, in an apparatus for separating salts and liquors, a displacement chamber having an inlet, an outlet for salts and a liquor overflow port, a superimposed chamber for the liquor containing the solid to be washed having an inlet and provided with an outlet for liquors and a restricted passage connecting said chambers for passage of solids from the superimposed chamber to the displacement chamber, the liquor outlet of the superimposed chamber being arranged relative to the liquor overiiow port of the displacement chamber at an elevation such that said passage will be located substantially at a static interface between the liquor bodies in said chambers, said passage being of suitable length to permit relatively small variations in the position of the interface between the liquids in the two chambers while at the same time maintaining said interface substantially within said passage.

6. An apparatus for separating solids and liquors comprising a displacement chamber having an inlet for liquor, an outlet for solids, and an outlet for liquor, a settling chamber for liquor containing solids thereabove, said second chamber having an inlet for liquor and suspended solids, an outlet for liquor and an outlet orifice for solids, said orifice discharging into the displacement chamber below the liquor outlet thereof, the relative elevations of the liquor outlets of said chambers and the relative spacing of the liquor outlet and outlet orifice of the settling chamber being such that said orice is disposed approximately at the static interface between the liquor bodies in the two chambers.

'7. An apparatus for separating solids and liquors comprising a settling chamber having an inlet for liquor containing suspended solids, an orifice outlet forsolids and an overflow outlet for liquor, a displacement chamber below said settling chamber having an inlet for liquor, an outlet for solids and an overflow outlet for liquor, the relative elevations of the liquor outlet of said displacement chamber and the liquor and orifice outlets of said settling chamber being such that there is created approximately on the plane including said orifice a static interface between the bodies oi' liquor in said chambers, the solids in the settling chamber being thus discharged into the displacement chamber substantially at said interface.

8. An apparatus for separating solids from suspension while recovering the liquor comprising a displacement chamber having an inlet for liquor, an overflow outlet for liquor and an outlet for solids, a superimposed settling chamber having an inlet for liquor containing suspended solids, an overiiow outlet for liquor and an annular outlet for solids near the bottom thereofv whereby solids are discharged into the displacement chamber, the relative elevations of both liquor outlets and the annular solids outlet being such that the compensating liquor heads in the two chambers establish a static interface approximately in that plane containing the orifice.

9. An apparatus for separating solids in suspension while recovering the liquor, comprising a displacement chamber having an inlet for liquor, an overflow launder near the top thereof and an outlet for solids, a superimposed settling chamber having sloping walls, an annular solids outlet orice at the bottom thereof, an annular conical bottom joining the inner edges of said annular orifice, an overflow launder for liquor and an inlet near the middle at the top thereof, the relative elevations of the launders and the annular solids outlet being such that the orifice lies substantially within a static interface between the liquor bodies in said chambers.

WILLIAM I-I. ALLEN. WILLIAM A. GALE. CHARLES F. RITCHIE.Y 

